New Product Development

Managing engineering teams in development and production of modular steel control buildings.• Responsible for mechanical design and documentation of control buildings, relay panels, and medium voltage switchgear assemblies.• Department turnaround – took over an engineering department with high turnover and limited processes, and developed a strong team and robust documented processes.• Grew team 60% in two years, while increasing output, reducing engineering errors, and increasing on-time delivery.• Implemented formal training programs and tracking for new engineering resources.• Created and implemented Document Control processes to manage drawing revisions and version control across disciplines, from initial sketches to finished as-built shop drawings.• Drive project management and scheduling process changes to reduce non-value added time and increase reporting accuracy.• Developed and presented Monthly Key Performance Indicators to track improvements and provide visibility to Executive Management.• Improved engineering manufacturing support and reaction time by creating clear responsibilities and reporting structures, developing issue tracking system, and increased accountability.

Director of New Product Development for Spa division, responsible for driving engineering, design, marketing, and manufacturing teams to bring new products and features to market. Lead and manage a team of project managers, engineers, designers, and technicians to complete large and small projects on time and on-budget. Lead New Product brainstorming and strategy efforts to create a product roadmap for multiple brands.

New Product Development, Project Management, Mechanical Engineering, Manufacturing, Sourcing, Testing, Warranty Reduction, Product Management, Marketing, Business Development.

Designed and developed a novel, patented new concept for fitness equipment. Started a new company to build and sell the EVO family of indoor cycles.

Served a dual role in Marketing and Customer Services, with the goal of managing and growing a $10M product line, while improving operational efficiencies and customer satisfaction. Shared P&L responsibility for the Customer Services group, specifically spare parts revenue, warranty cost, and extended warranty profitability. Responsible to develop and manage pricing, margins, and sales channels for spare parts and accessories, extended warranties, preventative maintenance contracts, and other services. Increased existing customer sales revenue over 10% through targeted promotional programs, e-mail and web advertisements, and developing relationships with 3rd party distributors.  Improved Customer Service Quality by implementing and leading training programs, call center scripting, and by creating and monitoring key department metrics. Served as technical expert in relation to company products for Customer Service field issues. Collected and analyze data for warranty costs, failure rates, 1st 90 day call rates, other metrics. Conducted direct sales of “second market” products (used, trade-ins, demo & consignment, excess and obsolete inventory, etc). Created revenue and cash-flow from “dead assets”.

Served as Cardiovascular Platforms Development Manager, responsible to lead cross functional teams in the development of electro-mechanical products for the commercial fitness industry.  Responsible to manage cost, schedule, and performance of new product development projects to be completed on time and within budget. Lead product research and marketing studies for new products. Lead New Product Development projects for OEM products manufactured by overseas suppliers. Lead cost reduction projects that produced annual savings of more than $2 million. Managed teams of 5 to 15 direct reports and outside contractors. Conducted stage-based design reviews with multiple engineering disciplines and cross-functional teams. Performed Trade Studies to determine the best feature set per cost analysis for new products. Specified tooling and manufacturing processes for medium to low volume production. Used engineering knowledge and critical decision making skills to guide technical development. Lead Field Update projects to service and upgrade fielded products. Vender selection and qualification, auditing, intervention, both domestic and international.

Lead Engineer for mechanical design in New Product Development of several products. Accomplishments include: Lead a team of 5 engineers and designers to create new products. Developed and designed unique new modality for successful cross-trainer type fitness product (2 patents issued). R&D of new elastomeric materials and forms for treadmill deck suspension. Lead development efforts and setup manufacturing in Taiwan and China for new products. Design and documentation in support of manufacturing of electro-mechanical exercise equipment and associated sub-systems.  Serve as product development engineer in charge of system design, component selection, fabrication and testing of new machine designs.  Perform stress analysis using Finite Element Analysis of welded and machined structures.  Work with Industrial Designers to define the aesthetics, ergonomics, and fit-form-function of new products.  Take input from marketing department, manufacturing department, and customer needs to produce robust, workable fitness equipment for the commercial market.  Carried out regulatory agency and in-house testing and evaluation of competitive products.  Designed and built tooling and assembly aids for manufacturing floor.  Research and specify capital equipment for manufacturing and engineering. Setup manufacturing processes, SOPs, training programs, and quality checklists. Performed trouble shooting and corrective actions for manufacturing and quality. Gather data from manufacturing and Customer Support groups to identify and track problems in the field.  Serve on multiple sustaining engineering problem solving teams to recommend and implement product improvements.  Held signing authority for Engineering and Manufacturing on all Engineering Change Orders Interface with manufacturing department and suppliers to implement changes.  Inventorship of multiple patented technologies.

Mechanical Design Engineer for specialty vehicle and automotive related projects. Responsibilities included: Design and documentation of vehicle chassis structures and manufacturing methods. (Ironman) Integration of hydraulic power steering system, engine and related sub-systems integration, fuel storage, fill, and evaporative emissions systems, and other component packaging and integration.  Oversaw fabrication and testing of structural and mechanical systems.  Worked with customers and suppliers to assure customer needs and relevant regulations were met. Researched current automotive manufacturing and design practices and products. Developed prototype components and assemblies for concept and production purposes.Worked with a cross-functional team on the development of various automotive related projects.

Team Losi is a manufacturer of Radio Controlled model vehicles intended for competitive racing.Accomplishments included: Mechanical design and documentation of all systems and components, development of new products, and project management. Completed several new racing vehicle design projects, from conceptual design and prototyping to tooling and production of complete kits.  Lead multiple development projects including tire compounds, tread design, suspension geometry, shocks and springs, gearing and drive components, materials, and manufacturing methods.  Perform all design tasks, 3D solid modeling, 2D drafting, stress analysis (FEA), prototyping, fabrication and assembly, testing, tooling design, troubleshooting and supplier interface. Extensive experience with plastics design and design for manufacture and assembly. Setup manufacturing processes for producing components and kits.

Responsible Design Engineer, responsibilities included:  Mechanical design and project management of Technology Development Program tasks in the satellite communications and electronic packaging field. Developed new forms of electronic packaging for ultra high frequency RF modules.  Designed test fixtures and oversaw testing methodologies and operations.  Worked with electrical and RF engineers to define requirements for development projects.